INDUSTRY LEADING VALVE ACTUATION NEWS FROM THE WORLD OF ROTORK

28
Celebrating
50 Years
in Control
YEARS
1957 - 2007
Rotork is Business of the Year SW
Excellence Award Winner
Company News
The latest news from Rotork
Focus on Gearboxes
Spotlight on Rotork Site Services
Inside:
COVER STORY:
Celebrating 50 Years in control.............. 3
COMPANY NEWS:
The latest company news....................... 4
CONTRACT NEWS:
The latest Rotork
contract success stories.............. 5 & 15
FEATURES:
Skilmatic update..................................... 9
Spotlight on Site Services.................... 10
Site Services news................................ 12
Product news........................................ 13
Focus on Gearboxes.............................. 14
PEOPLE NEWS:
Personnel news..................................... 16
28
INDUSTRY LEADING VALVE ACTUATION
NEWS FROM THE WORLD OF ROTORK
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Front cover montage:
Rotorks complete history of the electric actuator dating from
the 100A Actuator in 1957 to the IQ Pro introduced in 2006
[3]
28
COVER STORY
For more information on ROTALK articles and features contact Nicky Skinner at ROTORK Bath: +44(0)1225 733200 email: nichola.skinner@rotork.co.uk

Above: Alastair Spurr - Operations
Director (centre), with Tim Eggington
- Production Manager (left) and
shopfloor staff at the Brassmill
Lane factory.
Right: Rotork headquarters,
Brassmill Lane, Bath, UK.
Celebrating Fifty Years in Control
As Rotork celebrates its fiftieth
birthday, another landmark is
reached with the opening of the
companys first manufacturing
plant in China.
The new factory, in Shanghai, is
building Rotork Gears IW Range
secondary gearboxes for both the
local and export markets. Fifty years
YEARS
1957 - 2007
ago, when the first Rotork actuators
were being assembled at Jeremy
Frys Widcombe Manor home, this
would have been hard to imagine.
The first purpose-built Rotork
factory began life on a greenfield
site at Brassmill Lane in Bath in
1962. Today, the dramatically
expanded Brassmill Lane facility is
still the companys headquarters and
primary factory for the manufacture
of electric actuators.
By the end of the 1970s the
manufacture of electric and
fluid power actuators had been
established in the USA as well as the
UK and the manufacture of electric
actuators for the domestic market in
India had began in Mumbai.
During the last twenty years the
pace of expansion has continued to
increase, driven by the penetration
of new markets, innovative product
developments and acquisitions.
Further manufacturing plants in
the UK, USA, The Netherlands, Italy,
Germany, Malaysia and now China
have increased the total number to
ten. Between them, these plants
produce the most comprehensive
offering of electric, electro-hydraulic,
hydraulic, pneumatic, high pressure
gas and gas-over-oil actuators,
control systems, gearboxes and
accessories available from any single
manufacturer, giving Rotork its
unrivalled one-stop-shop capability.
AWT electric actuator test rigs at the Malaysian Factory A and K electric actuators at Chennai, India Fluid Systems factory at Lucca, Italy
IQ electric actuators at Rotork Inc., Rochester USA Gearbox production at Rotork Shanghai Jordan electric actuators at Jordan Controls Inc., USA
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COMPANY NEWS
Rotork Group company news from around the world
Rotork successfully defends
Intellectual Property
Rights in Europe
In a legal judgement on 11th April 2007, the Court of
The Hague, Netherlands, found Shanghai Autork Digital
Apparatus Co. Ltd guilty of slavish imitation, breach of
copyright and violation of design rights relating to Rotorks
award winning IQ and IQT series of actuators.
In addition Autork was found guilty
of infringing Rotorks internationally
recognised trademark.
In a wide ranging judgement,
Autork was ordered by the Court,
with immediate effect, to stop
infringing Rotorks proprietary
rights throughout the whole of the
expanded European Community.
The Court further instructed Autork
to remove infringing product from
storage addresses, distribution points
and customers. Autork, based in
Mid-Yunnan Road, Shanghai, PRC is
a trading organisation very closely
affiliated to Tefulong Group Co.
Ltd (formerly known as Zhejiang
Tefulong Machinery Co. Ltd) who
also trade as Wenzhou Greatork
Apparatus Co. Ltd. The President,
principal shareholder and legal
representative of these businesses
is the Wenzhou businessman and
property developer Mr Baoping Fang.
Further action against Tefulong,
its affiliated companies and legal
representative is ongoing with
Shanghai Peoples Court of China.
Rotork, currently celebrating its 50th
anniversary, has been responsible for
introducing many innovations within
valve automation and its products
are the result of extensive research
and development.
Rotork urges its customers and
users to be vigilant and wary of
inferior imitations of its products
and components that have not been
subjected to the same level of third
party approvals and certifications.
If in any doubt, customers are
requested to contact their nearest
official Rotork representative.
Rotork, currently celebrating its 50th anniversary, has
been responsible for introducing many innovations
within valve automation and its products are the
result of extensive research and development.
Centre of Excellence for
Fluid Systems opens in Spain
Rotorks premises in Spain have
been selected to be the tenth
Centre of Excellence for the Rotork
Fluid Systems Divisions pneumatic
and hydraulic actuation business.
Rotork Fluid Systems manufactures
a comprehensive range of valve
actuators, controls and associated
equipment, serving the oil and gas
exploration and transportation,
water and waste treatment, power
generation, chemical and processing
industries. Manufacturing plants
in Italy, Germany and the USA are
supported by a growing number of
Centres of Excellence, strategically
located around the world to meet
the needs of local markets.
Each centre holds stocks, provides
application engineering and the
packaging of control components
as well as the full range of sales,
contract, service, installation and
commissioning activities. Fluid
power actuation specialists at
the centres are able to provide
solutions to virtually any application
requirement.
The new facility in Spain joins
Centres of Excellence in Australia,
Canada, Germany, Italy, the UK, USA
(3) and Singapore, which
have opened in recent years as
Rotork Fluid Systems international
business has experienced
unprecedented growth.
Rotork is the outright winner
of the 2007 West of England
Business of the Year Award, a
prestigious annual event now
in its twentieth year, organised
by the international accounting
and consulting firm Price
Waterhouse Coopers.
The award recognises a companys
achievements and performance
across a broad range of aspects
including innovation, business
management, future outlook,
employee development and training,
health and safety, commitment to
the community and environmental
responsibility.
The rigorous selection procedure,
performed by a judging panel
comprised of leading figures
from industrial, financial and
business sectors, embraces the
submission of an extensive written
review of the business including
performance figures for the past five
years, followed by a detailed and
penetrative visit to the companys
premises.
Competition for the award was
fierce. In addition to Rotork the
six finalists consisted of eminent
companies in the construction,
property maintenance and business
management sectors and the
National Trust.
In the final analysis, however,
the Rotork package of business
achievement and innovation won
through, proving once again that
at the age of 50 the company
can still outperform the toughest
challengers.
Research and Development Director
Graham Ogden led Rotorks award
winning campaign, which follows
closely on last years success in
winning a 2006 Innovation and
Design Excellence Award.
Rotork wins Prestigious
Business of the Year Award
Rotork directors at the award ceremony
For more information on ROTALK articles and features contact Nicky Skinner at ROTORK Bath: +44(0)1225 733200 email: nichola.skinner@rotork.co.uk [
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CONTRACT NEWS
Rotork Group contract news from around the world
28
Wessex Waters first
formal framework
agreement for electric
valve actuators has been
awarded to Rotork in
the face of substantial
competition from
European manufacturers.
The agreement, which will run for
three years from the beginning of
2007, encompasses the supply of
electric actuators, control systems
and associated services including
the retrofitting of new actuators
on existing valves, service and
maintenance. Rotork has been a
supplier of valve actuators on water
and waste treatment plants now
owned by Wessex Water throughout
virtually all of its history. Generally,
Wessex Water installations now
utilise IQ and IQT Pro intelligent
electric actuators, featuring
market-leading non-intrusive
commissioning and information
transfer technologies which
combined with comprehensive
data logging abilities optimise plant
performance and facilitate predictive
maintenance by recording historical
valve operating data.
As a key control element in the
automated operation of modern
water and waste treatment plants,
the Rotork actuators proven and
reliable connectivity with the
industry-preferred Profibus open
control protocol has also made
an important contribution to the
framework selection decision.
The benefit of Rotorks Profibus
Highway Termination Module,
enabling actuator disconnection/
reconnection without disrupting
A Rotork engineer testing an IQ actuator on site at Highbridge
Wessex Water first for Rotork
High speed actuator
deliveries help to get
the gas moving in Egypt
Rotork Fluid Systems has
successfully completed a fast-
track valve actuation contract
for a new strategic natural gas
distribution pipeline in Egypt.
The contract involved the
manufacture of specialised gas-
over-oil actuators for main line
isolating valves on the 135 kilometre
Shoukaur to Hurghada pipeline.
Eleven actuators were required on
a fourteen week delivery schedule
within the period including
Christmas and New Year.
Built at Rotork Fluid Systems factory
in Lucca, Italy, the scotch-yoke RFS
Model GO 130 actuators will operate
24 inch Class 600 ball valves
manufactured by Egyptian
valvemaker Evaco. Rotork gas-over-
oil actuators are specifically adapted
for valve control in the remote
locations traversed by pipelines by
using the pressure of the gas in
the pipeline itself to operate the
valve. In addition to the standard
gas-over-oil specification, actuators
for this contract were fitted with
valvemaker requested options
comprising torque limiting devices
to protect valve stems and integral
back-up accumulators with a
stand-alone capacity of four valves
strokes.The Shoukaur to Hurghada
pipeline is owned by the Egyptian
gas transportation company GASCO,
who are organising engineering,
procurement, construction
supervision, commissioning and
start-up. Construction of the USD 60
million project which commenced
in May 2006 and will be completed
by mid 2007 is being performed
by Egyptian engineering contractor
Petrojet. The completed pipeline
will supply natural gas at the rate
of up to 5 MMSCMD (5 million
standard cubic metres per day) to
the Egyptian provinces of Shoukaur
and Hurghada. Rotork Fluid
Systems performance in securing
the successful completion of this
important contract was applauded by
GASCO Materials General Manager
Mr. Karem Mahmoud during a recent
visit to the Lucca factory.
Mr. Karem Mahmoud is pictured (right) at the Lucca factory with Fluid Systems
General Manager Sales, Vittorio Stefani.
communication to other devices
on the highway, was especially
appreciated. Wessex Water Contracts
Manager Russell Day commented: In
addition to a track record of reliability
and low cost of ownership, Wessex
Water has been impressed by Rotorks
performance with after sales service
and technical support. Price stability
and value for money were also taken
into account during our decision
process with regard to this important
item of equipment for Wessex Water.
RFS Model GO 130
actuators will operate
24 inch Class 600 ball
valves manufactured
by Egyptian
valvemaker Evaco.
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In the latest of several similar contracts in the Middle
East, Rotork electric, hydraulic and pneumatic actuators
have been ordered for two major new gas developments
in the United Arab Emirates.
Single source capability and local support
earns multi-technology actuator contracts
Rotork is a single-source supplier of electric multi-turn (top left), hydraulic linear (top
right) and pneumatic quarter-turn valve actuators for the OGD3 and AGD2 projects.
AGD2 overall project manager is
Foster Wheeler and completion is
scheduled for the first quarter of
2008. Rotorks actuator contracts
have been placed by Bechtel in
the USA and UK, Snamprogetti
and the National Petroleum
Construction Company.
The Habshan Onshore Gas
Development Phase 3 (OGD3) and
Asab Gas Development Phase 2
(AGD2) will provide a huge resource
of natural gas to liquids (NGL)
and condensate for the refinery at
Ruwais to assist with the expansion
of the petrochemical industry in
Abu Dhabi. In addition both projects
will generate substantial volumes of
liquid gas which will be re-injected
into the oil fields for pressure
stabilisation.
Rotork IQ intelligent electric
actuators have been ordered
throughout the $2,300 million
projects, which involve the
construction of NGL and
condensate recovery facilities at
the Habshan onshore field and a
110 kilometre pipeline to Ruwais,
where new storage tanks are also
being constructed. Six hundred
IQ actuators have been ordered,
together with up to sixteen Rotork
Pakscan two-wire digital control
systems. In addition, approximately
one hundred quarter-turn
pneumatic and linear hydraulic
actuators are being supplied,
providing a single source for multi-
technology actuation products that
simplifies the contractual route
for the four contractors involved.
Contractual negotiations have
been further assisted by Rotorks
increased commitment to the area,
as demonstrated by the presence of
a Rotork Middle East Regional Office
in Abu Dhabi.
For the OGD3 and AGD2 projects,
regular meetings with the three
end-user clients GASCO, ADCO and
TAKREER resulted in Rotork being
awarded all five of the actuator
packages on offer. The OGD3/
CONTRACT NEWS
Rotork Group contract news from around the world
The Italian Jobs
Rotork Italy has won an exclusive
framework agreement with Kuwait
Petroleum Italy for the supply of
electric actuators at the giant Naples
tank farm. The agreement covers the
motorisation of 175 manual wedge
gate valves with IQ actuators in a
contract that will be completed in
February 2008.
In recent years more than 100 IQ
actuators have been installed on the
site and thanks to the high technology
of the design and the on-site service
provided by Rotork the customers
Technical Direction team has decided
to standardise on the product. The
new contract is Rotork Italys second
framework agreement with the Italian
fuel distribution industry. The first was
signed in 2001 with API (Anonima
Petrol Italiana) for the Ancona Refinery,
where more than 400 IQ actuators
and six Pakscan loop control systems
are now in operation. Rotork Italy is
also busy with the power generation
industry in the country, where more
than 1200 IQ actuators have been
installed since 2000 as a result of new
energy production laws. Torrevaldaliga
the largest power station in Italy has
been refurbished in two stages, in 2003
and 2006, resulting in the installation
of approximately 450 IQ actuators with
Profibus connectivity in the two parts of
the site, Torre Nord and Torre Sud.
Rotork received most of the orders from
ENEL, who had overall responsibility for
the refurbishment of both parts and
had been using IQ actuators at another
plant at La Casella since 2000. Further
orders were received for the boiler areas
from Ansaldo Caldaie, who specified a
preference for the IQ actuator, and from
damper manufacturers Stejasa in Spain
and Damper Technology in the UK.
Following actuator installation Rotork
engineers attended the site in order to
assist and train DCS technicians from
ABB on Torre Nord and Siemens on
Torre Sud.
For more information on ROTALK articles and features contact Nicky Skinner at ROTORK Bath: +44(0)1225 733200 email: nichola.skinner@rotork.co.uk [
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CONTRACT NEWS
Rotork Group contract news from around the world
Rotork Fluid Systems has received an order valued in
excess of one million Euros for the actuation of valves
in the feed gas preparation area of the Pearl GTL (Gas to
Liquids) project in Qatar, the largest plant of its type in
the world, due for completion by the end of the decade.
The order has been placed by
Orton Industrial Valves in Italy and
involves the supply of a total of
180 GP and CP range pneumatic
actuators for the operation of
butterfly valves in sizes ranging
between 8 and 24 inches.
Built by Chiyoda of Japan, the
Pearl feed gas preparation plant
comprises two trains of processing
units with a total capacity of 1600
MSCFD (million standard cubic feet
per day) of natural gas, equivalent
to 8 MMTPA (million tonnes per
annum) of LPG. The plant will
supply feed gas to the GTL core
unit for the production of 140,000
barrels per day of clean, high quality
fuels and products.
Negotiations for the Rotork
contract have been assisted by
close co-ordination between
Rotork Fluid Systems area offices
in the Middle East and Korea as
well as the factory at Lucca in Italy,
where the sales support team
has been on hand to ensure the
best possible support to Chiyoda
and the valvemakers involved
throughout the bidding process.
The Pearl GTL project is being
developed by Qatar Petroleum
and Qatar Shell GTL Limited under
a Development and Production
Sharing Agreement with the
government of the State of Qatar
signed in 2004. The project
is expected to produce three
billion barrels of oil equivalent
wellhead gas over the period of
the agreement. A total of USD
10 billion of contracts have been
awarded to-date, including all the
major engineering, procurement
and construction contracts.
This photograph, taken at the premises of Orton in Italy when the Rotork contract was
signed, shows (from left to right): Christian Ferdenzi - Area Sales Manager, Rotork Fluid
Systems. Enrico Vitale - Area Sales Manager, Orton. Peter France - Managing Director,
Rotork Fluid Systems. Enzo Stendardo - Marketing Manager, Orton. Alberto Aliani -
Managing Director, Orton. Vittorio Stefani - General Manager Sales, Rotork Fluid Systems.
The completion of the new
Reliance refinery at Jamnagar
on the west coast of India
scheduled for the end of
2008 will create what is
being described as the largest
refinery complex in the world.
The new refinery is under
construction on an area adjacent to
the existing refinery, tank farm, export
facility and power station, a giant
project in itself which was completed
in the late 1990s. At both sites,
Rotork IQ intelligent electric valve
actuators have been widely specified,
generating an installed quantity of
several thousand motorised valves.
More than 2500 IQ actuators are now
in operation at the original refinery,
which has a daily production capacity
of 660,000 barrels. The new plant,
which will require a similar number
of IQ actuators, will nearly double
this capacity, producing mostly
diesel, petrol and jet fuel. Bechtel is
responsible for detailed engineering,
project management, site support
and construction supervisory services.
Rotork is currently receiving orders
from valvemakers including Metso
More actuators specified for
Giant Refinery Expansion
Automation and Tyco Valves &
Controls. As with the existing refinery,
many of the new actuators will be
controlled by the Rotork Pakscan two-
wire digital control system, radically
reducing the cabling costs involved
in linking large numbers of field units
over long distances to Distributed
Control System equipment housed
in centralised control rooms. The
site will be amongst the first to
be equipped with Rotorks third
generation P3 version of Pakscan,
featuring increased information
capacity and improved user-
friendliness. The P3s enhanced
specification includes Ethernet
connectivity, a built-in secure web
server and the logging of host
messages, field unit commands
and status changes with time
synchronisation capability.
A new master station HMI (Human
Machine Interface) screen replaces
the text-only predecessor with clear,
easy-to-read icons to facilitate the
navigation of screen menus for
configuration of controls, alarms and
diagnostics. The new IQ actuators also
incorporate enhanced functionality
features as standard for improved
long term asset management. For
example, an integral data logger
stores historical operating data,
including the sequence of valve
torque profiles. This information can
be downloaded and analysed with
Rotorks PC-based IQ-Insight
software to establish predictive
maintenance schedules or identify
potential problems.
Valve actuation contract at
Worlds Largest Gas to Liquids Project
Instrument engineers from Reliance photographed during factory acceptance tests on
the first consignment of Pakscan P3 master stations to be shipped from Rotork Bath.
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CONTRACT NEWS
Rotork Group contract news from around the world
Rotork Fluid System heavy duty pneumatic valve actuators have
been ordered for the first next generation upgrading plant for
the processing of bitumen and heavy oils.
Next generation
heavy oil upgrading
plant chooses Rotork
Customised solution at
the Copper Mine
Kennecott Utah Copper
has the largest open
pit copper mine in the
world, from where ore
containing just 0.6%
copper is blasted out,
crushed, concentrated,
smelted and refined to
produce 99.99% pure
copper metal.
Within this rugged industrial
process a number of existing
linear actuators were causing
problems with maintenance
and production in the
flotation cell area, where
the ore is mixed with water,
chemicals and air to produce
the 28% copper concentrate
which then goes on to be
smelted.
Rotork worked closely with
Kennecott Copper and
Industrial Solutions of Utah
to successfully replace the
problematic actuators with
custom-designed Rotork
linear pneumatic units, three
of which are pictured here.
Bitumen, which is obtained
from oil sands, and heavy oils
comprise the bulk of raw material
resources for the Canadian oil and
petroleum industries. They are
said to represent the future new or
incremental supply of crude oil for
the world and North America
in particular.
Canada has enormous resources of
these raw materials which are thick,
tar-like and extremely viscous,
making them difficult to transport
by pipeline and refine unless they
are first diluted and then upgraded
to remove contaminates.
Current upgraders in North
America, which are operating at
near-full capacity, use technologies
that are capital intensive and
attract high operating costs
according to BA Energy Inc, who
are constructing the Heartland
Upgrader at Strathcona County,
northeast of Edmonton in Alberta.
Described as a techno-economic
breakthrough, the Heartland
Upgrader utilises next generation
technology to upgrade bitumen
and heavy oil to synthetic crude
oils and other petroleum products
without the need for a hydrogen
production facility.
On the first phase of the project
Rotork is supplying CP and GP
range spring return actuators
mounted on Leusch trunnion
mounted ball valves in sizes up to
30 inches. The actuators will be
fitted on the valves and packaged
with control elements at Rotork
Fluid Systems regional Centre of
Excellence in Calgary.
Duties for the actuated valves
include diluted, desalted and
emulsified bitumen, sour
water, natural and sweep gas,
steam, warm de-aerated water,
asphaltene/water and the
intriguing sounding DRU stripper
bottoms! On completion of
Phase 1 in 2008 the Heartland
Upgrader will have a capacity of
up to 77,500 barrels per day of oil
sands bitumen blend, which will
rise to approximately 260,000
barrels per day when the upgrader
is fully expanded by 2013. The
project is being constructed by the
engineering partnership of Jacobs
Engineering Group Inc and Larsen
& Toubro Ltd.
Rotork enjoys a long association with the Canadian oil sands industry, with thousands
of actuators installed in numerous locations.
For more information on ROTALK articles and features contact Nicky Skinner at ROTORK Bath: +44(0)1225 733200 email: nichola.skinner@rotork.co.uk [
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SKILMATIC UPDATE
Rotork Group contract news from around the world
28
Following the introduction of the SI range of intelligent electro-
hydraulic actuators, the demand for Skilmatic actuators is racing
ahead throughout the world. So much so that significant upgrades
to manufacturing capacity from order entry to final inspection
have been implemented at the UK Skilmatic factory in Leeds.
Strong Sales, Increased Capacity
New staff, including assembly
operators and an additional
contracts/production engineer,
have been employed whilst the
manufacturing facility has moved
to a newly refurbished building
area with more casting washing
and assembly space and segregated
service areas.
In addition, new tooling for the
sub-assembly and assembly areas
has been installed in order to
increase manufacturing capacity.
Finally, computerised function
and cycle testing has also been
introduced in order to reduce final
inspection times.
All in all, says Howard Slack,
Rotork Skilmatic Divisions Director,
we are making the upgrades
in order to achieve immediate
manufacturing improvements and
reductions to our delivery dates for
the Skilmatic SI actuator range.
we are making the upgrades in order
to achieve immediate manufacturing
improvements and reductions to our
delivery dates for the Skilmatic SI
actuator range.
Top: Work in progress on the new Skilmatic manufacturing plant.
Above: Manufacturing underway again
One recent Skilmatic SI contract is helping to improve the supply
of natural gas to the Republic of Ireland. The order, from Bord
Gais, was awarded to Rotorks agent in Ireland, Pegler and Louden
(BSS), who recommended the Skilmatic electro-hydraulic solution
as an improvement to the pneumatic actuators originally used
on the application.
Natural Gas in Ireland
Bord Gais is responsible for
the supply, transmission and
distribution of natural gas in
Ireland, 25% of which enters the
country through four gas metering
lines at the site where the Skilmatic
actuators are now installed.
Each metering line has been
equipped with two failsafe, spring-
return modulating Skilmatic
SIZL actuators, retrofitted on
existing CCI globe control valves.
The valves perform the critical
duty of controlling the gas flow
and pressure, so precise valve
positioning is vital. Each Skilmatic
SI-ZL350 actuator provides an
output torque of 8900 lbf through
a 300mm stroke length, with a
positional accuracy of more than
99.98%.
The actuators are certified for
hazardous area operation to
ATEX ll2G EExd llBT4. Installation
and commissioning was performed
by engineers from Exeeco APS
(Actuators, Projects & Service)
Division.
Two of the completed Skilmatic
actuator installations on the
Bord Gais project.
The actuators are
certified for hazardous
area operation to
ATEX ll2G EExd llBT4.
To further develop Rotorks
services in the areas of
maintenance, management and
upgrading of installed actuation
assets to ensure that we can fully
support and satisfy the increasing
demands from our customers on
a global basis.
Grant Wood - Director of the Site Services Division
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SPOTLIGHT ON SITE SERVICES
Rotork Group Features from around the world
Rotork Site Services, the new projects, service and retrofit division,
is now active in 47 service centres in over 20 countries around
the world, with agents providing support services in another
55 countries, bringing the total number of expert technicians
supporting Rotork customers to well over 1,000.
At the launch of the division in 2006, director Grant Wood described
his aspirations for the new service as:
What does it
all mean?
Emergency and Planned Service:
Whatever the type of actuator, in all areas (including hazardous
environments), we will respond to customers requirements. Some
customers require guaranteed emergency response times, others
require planned response for all types of actuator work including:
installation, commissioning, upgrading, connection and installation of
bus communication systems, troubleshooting and repair of damaged or
deteriorating assets
Actuator Overhauls:
After a long service life some customers prefer their actuators to be
completely overhauled rather than replacing them with new ones. In
our workshops we completely strip and rebuild actuators, returning
them to their original state.
Shutdown Outages:
We can support customers in making sure that all their actuators are
fully operational and that they meet tight shutdown deadlines. For
example some power stations look for us to remove and overhaul
in our workshops over 200 actuators when taking a unit out for
maintenance. We do this, reinstall and commission the
actuators and where requested carry out additional actuation projects
simultaneously to ensure that customers make the most of their plant
shutdown time.
Health Checks:
Some customers lack detailed information on their assets, making it
difficult to prioritise maintenance and replacement investment. We
can carry out a detailed and intrusive inspection of the actuators and
combine this with build data from our own databases to give customers
a holistic view of their assets.
Preventative Maintenance:
Regular scheduled maintenance to enhance the integrity of actuators
and their associated valves. This service is typically sought by customers
looking to maximise the uptime of their plant.
Retrofitting actuators to existing valves:
We have a wealth of experience in fitting actuators to valves, penstocks
and dampers that are already installed as part of existing plant.

When asked to elaborate on how the service is actually tailored to meet the specific
needs of customers, Grant provided this comprehensive explanation:
[11] For more information on ROTALK articles and features contact Nicky Skinner at ROTORK Bath: +44(0)1225 733200 email: nichola.skinner@rotork.co.uk
28
Rotork Group Features from around the world
SPOTLIGHT ON SITE SERVICES
Whether customers are replacing obsolete actuators, changing power
sources or motorising manual valves we offer a tailor made solution to
meet customers specific requirements.
Factory fitting of actuators to new valves:
The careful assembly of valve and actuator is critical to ensure that an
automated valve performs correctly and reliably.
Whilst this service is often carried out by valve manufacturers, if there is
a need we can carry this out on a customers behalf.
Extended scope projects:
This is a growing requirement and some of our service teams have the
wide range of skills necessary to offer a one stop shop to automate
part or all of a customers process.
Our capabilities cover all of the installation phases (scoping, design,
procurement, manufacturing, installation, commissioning) on the
broad scopes that typically surround actuation projects.
Site Safety: Remote
Operated Shutoff
Valves (ROSoV)
Safety is one area where Site Services is increasingly active,
following the report into the Buncefield oil depot accident in
the UK at the end of 2005.
One of the immediate actions called for is the installation of
Remote Operated Shutoff Valves (ROSoV) to safeguard similar
sites. Rotork has therefore produced a ROSoV publication to
describe the actuation products and fire protection solutions
that are available for this critical duty through the services of
the Site Services Division.
Contact your nearest Rotork office to obtain a copy or
download it from www.rotork.com.

[
12
]
SITE SERVICES NEWS PRODUCT NEWS
Rotork Group product news from around the world Rotork Group contract news from around the world
When disposed of they blend
into the methane stream from
decomposing matter. Unless
they can be removed they render
the methane unusable for the
engines used in the biogas to
energy plants installed at landfill
and sewage treatment works.
The solution is to install specialised
filtration equipment to remove
these troublesome gases. PPTek,
a UK manufacturer of the filters,
recently supplied a system to
the Severn Trent Stoke Bardolph
Sewage Treatment Works in
Nottinghamshire, where engineers
from Exeeco successfully carried out
the installation. Martin Cheetham,
Exeeco Divisional Director explains:
Without any actuators involved,
this job was unusual for us and
enabled us to demonstrate our
extended capabilities on an
innovative solution to a process
problem that is common across
sewage gas and landfill gas power
generation systems throughout
the world.
Below: The PPTek siloxane removal plant installed by Exeeco at Severn Trent Stoke Bardolph STW.
The performance of Rotork Indonesia throughout
an actuator service contract at a petrochemical
plant has won a top award for Rotork Service
Engineer Dedi Supriadi.

Supervisors Award
for Rotork Indonesia
Siloxane removal -
another first for Exeeco
An unfortunate side effect of the replacement of CFC gases
in cosmetics, deodorants and other consumer products is the
damage to methane powered generating equipment in sewage
treatment plants caused by the Siloxanes that are now in
widespread use in these products.
The PT Chandra Asri plant is
situated at Cilegon in Banton,
approximately 120 kilometres west
of Jakarta. Built in 1997, the plant
is home to many Rotork actuators,
some of which required servicing
during a turn around, or outage, in
November 2006. Rotork Indonesia
received the inspection and service
contract for fourteen A Range
actuators mostly 70As installed
on Class 150 Friatec through-
conduit gate valves in sizes up to
48 inches located in the ethylene
plant. The successful completion of
the contract was marked by Dedis
selection as the best supervisor
from all fifteen maintenance
contracting companies involved in
the turn around, with top marks for
safety and zero lost time injuries.
Rotorks achievement was marked
by the award of a Certificate of
Commendation to Dedi at PT
Chandra Asris Jakarta offices in
February 2007.
Edi Supriadi is pictured at work with one of the actuators at Cilegon and with his
Certificate of Commendation awarded by PT Chandra Asri.
For more information on ROTALK articles and features contact Nicky Skinner at ROTORK Bath: +44(0)1225 733200 email: nichola.skinner@rotork.co.uk [
13
]
28
SITE SERVICES NEWS PRODUCT NEWS
Rotork Group product news from around the world Rotork Group contract news from around the world
Rotork IQPro electric actuators are now available with a Safety
Integrity Level (SIL) option for applications requiring SIL 2 and 3*.
With impending certification by TV, the SIL option can be
specified with any new IQ or IQT actuator or retrofitted to
existing actuators supplied since 2000.
SIL option for IQPro - TV approval imminent
Reliability has always been the
overriding priority for Rotork
electric actuator design and
manufacture, earning a reputation
that is unrivalled in the industry.
With the advent of standards to
quantify and achieve functional
safety in hazardous processes, the
reliability of equipment to perform
the required safety function must
now be ensured and defined with
auditable data.
Rotork has combined the inherent
design excellence of the IQ actuator
with the design and analysis
demands of IEC 61508 and IEC
61511 Standards to produce the
SIL option.
The Rotork SIL safety PCB
assembly monitors the standard
IQ/IQT control board and provides
diagnostic coverage and redundant
control in order to carry out the
desired safety function if an invalid
command signal is generated and/
or if the standard actuator control
system fails.
A safety function status relay
provides indication of the actuator
availability and redundant safety
function operation, with the same
status duplicated locally on the
actuator display.
Two safety functions
are available:
The Stayput function prevents
movement on a detected failure,
the actuator staying in its current
position. This is applicable to IQ
and IQT actuators.
The ESD (Emergency Shut Down)
function is selectable to move
fully closed, fully open or stayput.
This is applicable to IQ actuators
only. For more information or a
comprehensive description of SIL
options for Rotork electric or fluid
power actuators, contact
pete.hirst@rotork.co.uk.
*Where SIL3 is required, IQ Pro-SIL
may also provide coverage where 1 out
of 2 (1oo2) architecture is employed.
Actuators pass 7 day, 45 metre submersion test
Rotorks standard IP68 electric actuator enclosure is
designed to survive total submersion to a depth of 7
metres (23 feet) for 3 days, but recent test programme
has shown that it is capable of withstanding far worse
conditions for more than twice as long.
Above: Actuators positioned in test
chamber before the lid was attached.
Right: The IQT electrical housing and
terminal compartment, showing no signs
of damage after the test.
The test has confirmed the actuators
ability to survive for seven days whilst
submerged at a depth of 45 metres
(150 feet), conforming to the strict
standards of IPX8.
Performed at Rotorks R & D
department in Bath (no pun
intended!), the IPX8 test was
engineered by Rotork Houston with
the offshore oil platform, floating
production and storage industries
in mind. In these harsh operating
environments there is a risk of
extended periods of total submersion
at considerable depths and it is
important to know that the actuators
will still operate in these conditions.
Rotork IQT electric and Skilmatic
electro-hydraulic units were used in
the test, representing the types of
actuators often specified for electric
isolation and failsafe valve duties in
offshore and marine applications.
During the test the actuators were
remotely operated several times and
both types performed successfully
with no ingress of water into any
electrical housings.
[
14
]
FOCUS ON GEARBOXES
Rotork Group Features from around the world
Spotlight on Manual Gearboxes
Rotork manual gearboxes are
mostly manufactured at the
factory in Losser, which first
opened as Alecto in 1984, was
acquired by Rotork in 1998 and
became Rotork Gears BV in 2002.
The plant is one of five Rotork
Gears manufacturing centres,
the others being in the UK, USA,
Italy and China.
The main product line at Losser is
a range of worm gearboxes with a
maximum output torque of 32,000
Nm. The self-locking quarter-turn
design is suitable for ball, butterfly
and plug valves and manufactured
in a range of materials
encompassing aluminium, cast
iron and stainless steel. Gearboxes
are assembled from standard sub-
assemblies stocked at the factory
which are machined to meet the
In the first significant order of its kind for Rotork Valvekits,
the company is supplying sixty special low temperature duty
gearboxes to Bestobell Valves.
More subsea success
for Rotork Gears
In the latest of several recent
similar successes, Rotork
Gears has won subsea
gearbox orders for the KOC
crude oil export facilities
project in Kuwait.
The ability to meet critical delivery
schedules with top quality products
enabled Rotork Gears to fend off
fierce competition from European
manufacturers and secure the
contract, which is on one of the
largest and most prestigious oil sector
projects in the area.
Rotork Gears was selected by
valvemaker Velan Srl Italy to supply
Model WGS gearboxes. They are
mounted on Velan 56inch forged
steel, fully welded subsea trunnion
mounted full port Class 300 ball
valves.
The gearboxes are equipped with
pressure compensators, high
visibility T position indicators, direct
mounted ROV (remote operating
vehicle) inputs and stainless steel
handwheels with chain and clip for
emergency operation in the event of
ROV failure.
Rotork Valvekits wins LNG project order
The Model AB 1250W hand
operated gearboxes will be fitted
to Bestobell float level isolation
valves on LNG cargo carriers
under construction in Korean
shipyards. Valvekits has worked
closely with Bestobell to ensure
that the specifications and safety
levels demanded by this cryogenic
application have been adhered to
during contract discussions. As a
result of this success, further orders
for the Bestobell valves have now
been received as the ships owners
Qatargas have specified them for
their LNG fleet.
customers specification. Once
assembled, optional extras such
as switchboxes are fitted. Further
options include chainwheels,
square caps, padlocks and
extensions between the valve and
gearbox or between the gearbox
and its handwheel. The modular
approach to manufacture enables
the gear- boxes to be produced
with maximum speed and sold
at economical prices. In addition
to standard products, the factory
is also capable of manufacturing
special designs to meet specific
customer requirements. All
products undergo rigorous testing
and inspection routines prior to
shipment from the factory.
The workshop (below) photograph shows
an example of a large gearbox fitted to a
pneumatically actuated ball valve for a
customer in Germany.
[
15
]
CONTRACT NEWS
For more information on ROTALK articles and features contact Nicky Skinner at ROTORK Bath: +44(0)1225 733200 email: nichola.skinner@rotork.co.uk
Rotork Group contract news from around the world
The City of Fort Worth Water Departments Village Creek Wastewater Treatment
Plant serves more than 880,000 people and numerous industries in twenty-two
communities by treating up to 300 million gallons of wastewater each day.
The future is bright for Rotork at Fort Worth
28
Rotork Fluid Systems at Rochester
has supplied pneumatic and
gas-over-oil actuators to DHV
Industries for a project to build a
new gas pipeline in Vietnam.
The PM3 Ca Mau Pipeline is part
of the Gas Power Fertilizer Co-
ordination Project to supply natural
gas to an integrated power and
fertilizer plant in Ca Mau Province.
Originating on the Bunga Raya-B
(BR-B) platform in the Gulf of
Thailand the pipeline includes a 298
km subsea section, shore crossing
and landfall station, 27 km onshore
section with line block valves, gas
distribution station and supply
pipeline to the power and fertilizer
plant. The completed pipeline
is expected to have a maximum
capacity of 2 BCM (billion cubic
metres) of natural gas per annum.
Actuators for Vietnam pipeline
Rotork Fluid Systems is supplying
CP and GP range pneumatic
actuators for a new gas processing
facility in Egypt.
As part of the contract a HIPPS
(High Integrity Pressure Protection
Systems) test was successfully
performed on the GP actuators,
witnessed by a large contingent
from the valvemaker customer
CCI, including the companys vice
president Mr. Flavio Ricotti. The six
GP actuators subject to the HIPPS
test certification will operate Truflo
ball valves.
The remaining total of 170 GP and CP
actuators, supplied to LCM Italy, will
be installed in the production areas
of the new facility, which will boost
output at the Salam gas plant to 20
million cubic metres per day of gas
along with 66,000 barrels per day
of condensate.
The end user is Khalda Petroleum, a
joint venture between USA company
Apachi and Egyptian national
company EGPC. The plant, which is
being built by Egyptian construction
company Petrojet, is scheduled for
completion in 2008.
Egyptian contract includes HIPPS test
When Tim Allen became the
Departments I & E Manager a few
years ago his aim was to utilise
the best of breed valve actuator
across the district. At the time he
was wrestling with several different
manufacturers products in his
quest to standardise across the
board, so that all future upgrades
and additional processes would
incorporate first rate non-intrusive
technology. Rotorks Chris Carlisle
and Joe Etchegaray from local agent
FloTec worked hard to impress Tim
with the features of the Rotork
design and as a result, at the end
of a thorough technical evaluation
and bidding process, Rotork IQM
actuators were selected to replace a
competitors actuators coupled to
gearboxes on fourteen effluent filter
dump valve and two 96inch slide
gate valves in the contact basin. The
City paid a premium to ensure that
the technology met their demanding
specifications, but according to Jacob
Pena, I & E Supervisor at the plant,
this soon began to pay off during
the straight forward and efficient
installation and commissioning
programme. A team of four electrical
technicians were able to remove the
old actuators, install junction boxes,
rewire, mount and fully commission
nine Rotork actuators in a single
day. Jacob is convinced that he
couldnt have done this with any
other supplier.
Commissioning data was set up using
Rotork Insight software on Jacobs
PDA in his office and transmitted to
the actuators when the installation
work was completed. Jacob was
especially impressed with the ability
to dial in the torque and limit
settings. He also liked the fact that
he could set the number of turns to
close and open, which he says is not
available from other manufacturers.
Both Tim and Jacob agreed that
having reference footprint valve
torque profiles and the ability
to download actuator and valve
operating data on a routine basis
will be used to make preventative
maintenance decisions and
become an integral part of the
plants maintenance management
programme. All in all, the staff is
extremely satisfied with Rotork
technology.
So much so that a competitors
working demonstration unit, which
includes the manufacturers latest
non-intrusive setting and data
extraction features, is to be removed
from the facility and replaced with a
Rotork IQTM.
They say that Rotork Insight software
has no match with its sequential
event management and torque
profiles which provide very useful
data that is easy to interpret. For
the future the plan is to upgrade the
actuators in several more areas with
Rotork IQs, including the rest of the
fitter dump valves, digesters, aeration
basin, sludge valves and offsite pump
stations. The Village Creek facility
alone has more than five hundred
MOVs that will eventually retrofitted
with Rotork actuators as the budgets
become available.
Pneumatic and gas-over-oil actuators bound for Vietnam at the DHV factory.
PEOPLE NEWS

[16]
UK head office
Rotork Controls Limited, Bath
tel 01225 733200
fax 01225 333467
mail@rotork.co.uk
USA head office
Rotork Controls Inc, Rochester
tel (585) 247 2304
fax (585) 247 2308
info@rotork.com
Rotalk is published and printed by
Rotork Controls Ltd. in the UK.
For more information on ROTALK articles and features contact Nicky Skinner at ROTORK Bath: +44(0)1225 733200 email: nichola.skinner@rotork.co.uk
28
Peter France appointed
Group Chief Operating Officer
From 1st October 2007
the Rotork Group will have
a new Chief Operating
Officer in the person of
Peter France. Peter (39) is
currently Managing Director
of Rotork Fluid Systems and
a Director of Rotork p.l.c.
Born in Rotorks home city of Bath,
Peter joined the company in 1989.
His career has encompassed UK
and international sales, service and
management duties for the electric
and fluid power actuator divisions
including the position of Director
and General Manager for South East
Asia during a time of rapid
expansion throughout the area
in the late 1990s.
Pictured on the Larsen & Toubro
stand at ADIPEC, this IQ Pro actuator
and AUDCO ball valve is one of the
many that have been ordered for
the Inter Refinery Pipeline Project,
where Rotork is supplying over 500
of the latest version Pakscan-enabled
IQ actuator with eight Pakscan hot-
standby master stations.
The new pipeline will link the
refineries at Sas-Al-Nakl and Ruwais
in the UAE, eliminating the current
need to transport products between
the sites by marine tankers, easing
shipping congestion in the busy
Umm Al Nar Channel and improving
environmental protection.
Pipeline IQ actuators
These finely honed athletes are a cycle team
sponsored by Rotork for a series of races, who
will raise company and product awareness
throughout the country whilst participating in
a sport that is rapidly growing in South Africa.
The idea was the brainchild of Rotork
salesman Kevin Froneman, who will be
travelling with the team and drumming up
business at the events.
Rotorks Reps get
on their bikes in
South Africa
DHV Industries manufacture gate,
globe, check, ball, wellhead and choke
valves at Bakersfield in California.
Their stand at the 2007 OTC Houston
show featured this trunnion mounted
pipeline ball valve fitted with a Rotork
spring-return pneumatic actuator.
Pictured with the exhibit are (left
to right): Ron Fortner DHV Sales
Manager, Eric Lingle DHV Vice
President and Sam Lingle DHV
Marketing & Sales Director.
At OTC Houston
At the same event the ASME
(American Society of Mechanical
Engineers) Offshore Technology
Golf Tournament has earned the
reputation of being one of the
premier events and has been a
sell-out for several years.
This year Rotork Fluid Systems
teamed up with their new distributor
in the Texas Gulf Coast area,
Equipment Valve & Supply Inc.,
to provide breakfast for the
participating golfers.
Pictured (left to right): Leo LaBorde-RFS,
John Nicholas and Jack Lee from Equipment
Valve & Supply and Charles Reaves RFS.
As the Managing Director of
Rotork Fluid Systems since 2001,
Peter has shaped the extensive
growth of the Division,
which now accounts for a
significant proportion of Rotorks
worldwide sales.
L to R: Candice Da Cunha (Marouns Autos), Kevin
Froneman (Rotork), Mannny Da Costa (Pro United
Contractors), Lorn Swart (One Time Airlines), Gert
Engelbrecht (Paltechnologies)
Rotorks Ashley Watkins is pictured on the exhibition stand with Mr. M. Marriappan,
Manager of Project Sales Europe and Middle East, Larsen & Tubro, India.